Films produced from ethylene interpolymer products

Patent metadata

Field	Value
Publication number	US-10023729-B2
Application number	US-201615134654-A
Country	US
Kind code	B2
Filing date	Apr 21, 2016
Priority date	Oct 21, 2014
Publication date	Jul 17, 2018
Grant date	Jul 17, 2018

Abstract

This disclosure relates to films comprising at least one layer of an ethylene interpolymer product. The ethylene interpolymer product comprises a first ethylene interpolymer, a second ethylene interpolymer and optionally a third ethylene interpolymer; wherein the ethylene interpolymer product has ≥0.03 terminal vinyl unsaturations per 100 carbon atoms and ≥3 parts per million (ppm) of a total catalytic metal; and optionally a Dilution Index, Y d , greater than 0. The disclosed ethylene interpolymer products have a melt index from about 0.4 to about 10 dg/minute, a density from about 0.900 to about 0.940 g/cm 3 , a polydispersity (M w /M n ) from about 2 to about 12 and a CDBI 50 from about 20% to about 98%. Further, the ethylene interpolymer products are a blend of at least two ethylene interpolymers; where one ethylene interpolymer is produced with a single-site catalyst formulation and at least one ethylene interpolymer is produced with a heterogeneous catalyst formulation.

First claim

What is claimed is:

1. A film, comprising at least one layer comprising an ethylene interpolymer product comprising:
(i) from about 5 weight % to about 60 weight % of a first ethylene interpolymer;
(ii) from about 30 weight % to about 95 weight % of a second ethylene interpolymer, and;
(iii) optionally from about 0 to about 30 weight % of a third ethylene interpolymer;
wherein said ethylene interpolymer product has ≥0.03 terminal vinyl unsaturations per 100 carbon atoms;
wherein said ethylene interpolymer product has ≥3 parts per million (ppm) of a total catalytic metal, and;
wherein weight % is the weight of said first, said second or said optional third ethylene interpolymer divided by the weight of said ethylene interpolymer product.

2. The film of claim 1 , wherein said ethylene interpolymer product is further characterized as having a Dilution Index, Y d , greater than 0.

3. The film of claim 2 , wherein said ethylene interpolymer product is further characterized as having a Dimensionless Modulus, X d , greater than 0.

4. The film of claim 1 wherein said ethylene interpolymer product has a melt index from about 0.4 to about 10 dg/minute; wherein melt index is measured according to ASTM D1238 (2.16 kg load and 190° C.).

5. The film of claim 1 wherein said ethylene interpolymer product has a density from about 0.900 to about 0.940 g/cc; wherein density is measured according to ASTM D792.

6. The film of claim 1 wherein said ethylene interpolymer product has a M w /M n from about 2 to about 12.

7. The film of claim 1 wherein said ethylene interpolymer product has a CDBI 50 from about 20% to about 98%.

8. The film of claim 1 wherein said ethylene interpolymer product is further characterized by;
(i) said first ethylene interpolymer has a melt index from about 0.01 to about 200 dg/minute;
(ii) said second ethylene interpolymer has melt index from about 0.3 to about 1000 dg/minute, and;
(iii) optionally said third ethylene interpolymer has a melt index from about 0.5 to about 2000 dg/minute;
wherein melt index is measured according to ASTM D1238 (2.16 kg load and 190° C.).

9. The film of claim 1 wherein said ethylene interpolymer product is further characterized by;
(i) said first ethylene interpolymer has a density from about 0.855 g/cm 3 to about 0.975 g/cc;
(ii) said second ethylene interpolymer has a density from about 0.89 g/cm 3 to about 0.975 g/cc, and;
(iii) optionally said third ethylene interpolymer has density from about 0.89 to about 0.975 g/cc;
wherein density is measured according to ASTM D792.

10. The film of claim 1 wherein said ethylene interpolymer product is synthesized using a solution polymerization process.

11. The film of claim 1 wherein said ethylene interpolymer product comprises from 0.1 to about 10 mole percent of one or more α-olefin.

12. The film of claim 11 ; wherein said one or more α-olefin are C 3 to C 10 α-olefins.

13. The film of claim 11 ; wherein said one or more α-olefin is 1-hexene, 1-octene or a mixture of 1-hexene and 1-octene.

14. The film of claim 1 ; wherein said first ethylene interpolymer is synthesized using a single-site catalyst formulation.

15. The film of claim 1 ; wherein said second ethylene interpolymer is synthesized using a first heterogeneous catalyst formulation.

16. The film of claim 1 ; wherein said third ethylene interpolymer is synthesized using a first heterogeneous catalyst formulation or a second heterogeneous catalyst formulation.

17. The film of claim 1 ; wherein said second ethylene interpolymer is synthesized using a first in-line Ziegler Natta catalyst formulation or a first batch Ziegler-Natta catalyst formulation; optionally, said third ethylene interpolymer is synthesized using said first in-line Ziegler Natta catalyst formulation or said first batch Ziegler-Natta catalyst formulation.

18. The film of claim 1 ; wherein said third ethylene interpolymer is synthesized using a second in-line Ziegler Natta catalyst formulation or a second batch Ziegler-Natta catalyst formulation.

19. The film of claim 1 , wherein said ethylene interpolymer product has ≤1 part per million (ppm) of a metal A; wherein said metal A originates from a single site catalyst formulation used to synthesize said first ethylene interpolymer.

20. The film of claim 19 , wherein said metal A is titanium, zirconium or hafnium.

21. The film of claim 1 , wherein said ethylene interpolymer product has a metal B and optionally a metal C and the total amount of said metal B plus said metal C is from about 3 to about 11 parts per million; wherein said metal B originates from a first heterogeneous catalyst formulation used to synthesize said second ethylene interpolymer and optionally said metal C originates from a second heterogeneous catalyst formulation used to synthesize said third ethylene interpolymer; optionally said metal B and said metal C are the same metal.

22. The film of claim 21 ; wherein said metal B and said metal C, are independently selected from titanium, zirconium, hafnium, vanadium, niobium, tantalum, chromium, molybdenum, tungsten, manganese, technetium, rhenium, iron, ruthenium or osmium.

23. The film of claim 21 ; wherein said metal B and said metal C, are independently selected from titanium, zirconium, hafnium, vanadium or chromium.

24. The film of claim 1 ; wherein said first ethylene interpolymer has a first M w /M n , said second ethylene interpolymer has a second M w /M n and said optional third ethylene interpolymer has a third M w /M n ; wherein said first M w /M n is lower than said second M w /M n and said optional third M w /M n .

25. The film of claim 24 ; wherein the blending of said second ethylene interpolymer and said third ethylene interpolymer forms a heterogeneous ethylene interpolymer blend having a fourth M w /M n ; wherein said fourth M w /M n is not broader than said second M w /M n .

26. The film of claim 24 wherein said second M w /M n and said optional third M w /M n are ≤4.0.

27. The film of claim 1 ; wherein said first ethylene interpolymer has a first CDBI 50 from about 70 to about 98%, said second ethylene interpolymer has a second CDBI 50 from about 45 to about 98% and said optional third ethylene interpolymer has a third CDBI 50 from about 35 to about 98%.

28. The film of claim 27 ; wherein said first CDBI 50 is higher than said second CDBI 50 .

29. The film of claim 28 , wherein said first CDBI 50 is higher than said third CDBI 50 .

Assignees

• Nova Chem Int Sa

Inventors

• Yamane Marcelo
• Li Tieqi
• Wang Xiaochuan
• Dobbin Christopher
• Sibtain Fazle
• Taylor Kenneth Edward
• Khakdaman Hamidreza
• Brown Stephen John

Classifications

• C08L2205/025

  containing two or more polymers of the same hierarchy C08L, and differing only in parameters such as density, comonomer content, molecular weight, structure · CPC title

• C08L2203/10

  used for bottles · CPC title

• C08L23/0815 Primary

  with aliphatic 1-olefins containing one carbon-to-carbon double bond · CPC title

• B29K2105/0085

  Copolymers · CPC title

• C08F2500/03

  Narrow molecular weight distribution, i.e. Mw/Mn < 3 · CPC title